Modified frame face shipping and display container

ABSTRACT

The present invention is directed to an open-top container for shipping and displaying products which comprises a plurality of side walls and end walls. Bottom wall flaps are foldably joined to bottom edges of the side walls and end walls and are folded inwardly therefrom into overlapping relationship with one another to form a bottom wall closure. A respective plurality of beams foldably joined to upper edges of the respective plurality of side walls and end walls. Each of the plurality of the beams is defined by a shoulder panel and three folding flaps foldably joined to one another. A bumper sticker panel is foldably joined to upper edge of one of the plurality of side walls forming a partial top closure when the open-top container is in the shipping position and partially prevents products from falling out when the open-top container is in the displaying position.

CROSS REFERENCE TO RELATED APPLICATION

This application claims priority to U.S. provisional patent application Ser. No. 61/888,281, filed on Oct. 8, 2013, which is hereby incorporated hereinto by reference as if fully restated herein.

FIELD OF THE INVENTION

The present invention relates generally to containers for storing, protecting and displaying products and more particularly, to a shipping container that is easily converted into a display container that permits access to and display of the products shipped and contained therein.

BACKGROUND OF THE INVENTION

In shipping and displaying products, particularly in a retail setting, it is desirable to have a container which is easy to pack, sturdy and fully enclosed for protection of contents during storage and shipping, and also suitable for display at a retail site. For example, it is beneficial to have a container which allows a customer at a retail site to easily reach into the container and remove products for purchase. In such an application, it is desirable to have a printed area on the container which advertises or identifies the product. During storage and shipment of a container, it is important that a printed area be protected so that it remains attractive to the consumer at the retail location. Of course, the access opening through which a consumer can access the goods must also be closed during shipment and storage to prevent spilling of the product out of the container. Previously, the hand-set display container was a two-piece design; a heavy-weight glued-tube outer and a light-weight, tight-fitting, 3-sided flanged, U-shaped paperboard that had to be hand-inserted. The problems with this design were that the outer tears easily during the removal of the front tear-out panel that left jagged edges and often partially unfolded, and the time or labor or expense to insert the U-shaped paperboard.

There have been attempts in the past to manufacture a one-piece displayable container using perforated tear out panels, but these approaches have encountered several problems. For example, the perforations in previous attempts at such a design are; generally unprotected and located in areas that are highly susceptible to damage during shipping. This susceptibility to damage has led to premature failure of the perforations or has resulted in the use of stronger perforations requiring excessive force or tools to open.

Further, a perforated window, in itself, does not provide protection to any outside surfaces of a container, resulting in the potential for unattractive packages at retail sites due to gouges or scuffing from the distribution environment. Other attempts at creating a useful one-piece displayable container have used complex geometric designs requiring special equipment to manufacture, erect, and fill.

Therefore, it is desirable to provide a container for the shipping and display of products which can be easily manufactured on standard manufacturing and erecting equipment, and which further provides for easy alteration for display upon reaching point of sale and for convenient consumer access to the container contents.

SUMMARY OF THE INVENTION

The invention is directed to a “Frame Face” or an open-top shipping and display container for bags of refrigerated poultry and the like products. The phrase “Frame Face” generally means that due to the structure of the opening of the container, the open-top container can be used to store and ship products as well as being able to be rotated 90 degrees so that the container can be used as a display container. The material-handling requirement dictated that the bags and the container be shipped flat on their back, and then rotated 90 degrees into display position with an open face; eliminating all common display design choices since they are strong only in the shipping position. The shipping and display container had to be 1) strong in shipping position 2) have an open shop-able front that could survive weeks with up to four other displays container stacked on top of it and 3) has to be fast and easy to use within the retail's restrictive production environment. The present invention is a modified version of the applicant's prior U.S. Pat. No. 8,596,519, the disclosure of which is incorporated in full herein by reference. The side walls, the end walls, and the bottom walls are constructed substantially the same as and function in substantially the same way as described and shown in applicant's prior U.S. Pat. No. 8,596,519.

The advantages of the present invention, among others, are that the frame face display and shipping container resolves all the aforementioned problem herein above, while successfully addressing each of the material-handling requirements. It is a one-piece design in a heavy-weight paperboard grade, that is shipped either open-front or with an optional removable top plug panel. This combination of attributes delivers: 1) Good top-to-bottom compression in shipping position, 2) An open shop-able (e.g., excellent display and access to product) front that eliminates most of the “free panels” that could come unfolded and look unsightly, and 3) A “Frame-Face” that augments product presentation, faster and easier setup and loading in customer's production. The frame face display and shipping container design is useful especially for those products that are shipped in one position and rotated at 90 degrees to be used as display container, and is defined as a glued-tube structure with a customer-choice bottom closure like the RSC (regular slotted container) flaps illustrated at the side panels of the top (or, rather, “Front” when in the display position). The bottom of the frame face (still in display position) can have any of several profiles as defined hereinafter. The frame face display and shipping container can be configured in several alternative fashions. A bumper-sticker panel can be either taped/glued closed or a latching strap can be used. Either of these embodiments can be used with a top plug panel.

Accordingly, one aspect of the present invention is directed to an open-top container for shipping and displaying products which comprises a plurality of side walls. Bottom wall flaps are foldably joined to bottom edges of the side walls and are folded inwardly therefrom into overlapping relationship with one another to form a bottom wall closure. A bumper sticker panel is foldably joined to upper edge of one of the plurality of side walls forming a partial top closure when the open-top container is in the shipping position and partially prevents products from falling out when the open-top container is in the displaying position.

A top plug panel is used to enclose the open-top container when the open-top container is in the shipping position. The top plug is defined by a central panel having an extension tab and a pulling section formed on respective opposed longitudinal edges thereof. A pair of first detachable latch tabs extend outwardly from opposed lateral edges the central panel. The plurality of side walls further comprises a pair of handhold openings, each of which is formed in opposed plurality of side walls and each includes a hinge tab. The respective pair of first detachable latch tabs is engaged with the respective hinge tabs to securely hold the top plug onto the open-top container.

BRIEF DESCRIPTION OF THE DRAWINGS

A full understanding of the invention can be gained from the following description of the preferred embodiments when read in conjunction with the accompanying drawings in which:

FIG. 1 is an exploded perspective view of the shipping and display container and a top plug panel positioned in spaced relationship with respect to the container in accordance to the present invention;

FIG. 2 is a perspective view of four identical shipping and display containers of the type shown FIG. 1 and illustrating the four containers in displaying and stacking positions;

FIG. 3 is a plan view of a blank B1 used to form the shipping and display container shown in FIG. 1 in accordance to the present invention;

FIGS. 4-13 illustrate the folding sequences of the blank shown in FIG. 3 for constructing the shipping and display container shown in FIG. 1 in accordance to the present invention

DETAILED DESCRIPTION OF THE INVENTION

While this invention is susceptible of embodiment in many different forms, there is shown in the drawings and will herein be described in detail preferred embodiments of the invention with the understanding that the present disclosure is to be considered as an exemplification of the principles of the invention and is not intended to limit the broad aspect of the invention to the embodiments illustrated. In the present invention the use of prime character in the numeral references in the drawings directed to the different embodiment indicate that those elements are either the same or at least function the same or those elements are in the unfolded position. The phrase “Frame Face” generally means that due to the structure of the open-top container, the container can be used to store and ship products as well as being able to be rotated 90 degrees so that the open-top of the container can be used as a display container.

FIG. 1 is an exploded perspective view of a shipping and display container 10 having a top plug panel 26 positioned in a spaced relationship with respect to the container 10. The container 10 includes side walls 12 a, 12 b, end walls 14 a, 14 b, and a bottom wall 16 that are all foldably joined to one another. The container 10 has an open top or opening 18. Although the container 10 is characterized as having side walls and end walls, but one of the ordinary skilled in the art would appreciate that the end walls can be defined as side walls as well and the characterization of the side walls and end walls have no effect on the function or utility of the container 10.

The open-top container 10 includes shoulders 20 that provide bearing surface for the next container on top of it when the containers 10 are stacked on one another in shipping or display position. The frame face shipping and display container 10 also includes a bumper sticker panel 22 that is used to partially prevent products from falling out when the container 10 is in display position as clearly depicted in FIG. 2. Moreover, the bumper sticker panel 22 is also used to provide a place for application of the indicia and/or advertising label. Two handhold openings 24 a, 24 b are formed on the respective end walls 14 a, 14 b to facilitate handling of the container 10. Each handhold 24 a, 24 b includes a respective hinge tab 25 a, 25 b. The bottom wall flaps 16 a, 16 b, 16 c, and 16 d (shown in FIG. 6) are foldably joined to bottom edges of the side walls and are folded inwardly therefrom into overlapping relationship with one another to form a bottom wall closure 16. The bumper sticker panel 22 is foldably joined to upper edge of one of the plurality of side walls forming a partial top closure when the open-top container is in the shipping position. The top plug panel 26 is sized to cover the open-top or opening 18 of the container 10. The top plug panel 26 includes a central panel 28 and two lateral flaps 30 a, 30 b defined by respective fold lines 32 a, 32 b. The central panel 28 further includes an extension tab 34 projected outwardly from a longitudinal edge 36 and a pulling section 40. The pulling section 40 has two arc-like slits 42 and a light score line 44 so that the pulling section can be easily folded. Each of the lateral flaps 30 a, 30 b has a pair of first detachable latch tabs 46 a, 46 b. Each of the first detachable latch tab 46 a, 46 b has a pair of ears 50 a, 50 b. The top plug 26, side walls 12 a, 12 b, the end walls 14 a, 14 b, and the bottom wall 16 are constructed substantially the same as and function in substantially the same way as described and shown in applicant's prior U.S. Pat. No. 8,596,519. To enclose the container 10, the top plug panel 26 is position onto the opening 18 by inserting the extension tab 34 underneath of the bumper sticker panel 22 and the respective first detachable latch tab 46 a, 46 b are inserted into the respective handhold openings 24 a, 24 b such that the respective hinge tab 25 a, 25 b securely hold in place the respective ears 50 a, 50 b.

FIG. 2 is a perspective view of four identical shipping and display containers 10 of the type shown in FIG. 1 and illustrates the four shipping and display containers in stacking and display positions. It should be noted that each of the shipping and display containers 10 in FIG. 2 is rotated 90 degree to be in display position. When the container 10 is in stacking and display position, the respective shoulder panel 20 and the respective folding flaps (FIG. 3) foldably joined thereof will behaves like a beam that resist twisting and bending under load. Since the products inside each container are relatively heavy, then when the containers are stacked it is important that the beams sufficiently overcome the buckling force.

FIG. 3 is a plan view of a blank B1 used to form the shipping and display container 10 shown in FIG. 1. The blank B1 is substantially flat symmetrical with respect to its longitudinal axis thereof. The blank B1 is preferably an integral piece of a material such as continuous sheet of conventional corrugated cardboard. The blank B1 is cut along its outer margins to form its specific shape. The blank B1 is divided into side wall panels 12 a′, 12 b′ and end wall panels 14 a′, 14 b′ by three transverse parallel fold lines 54, 56, and 58. Upon folding, the side wall panels 12 a′, 12 b′ and end wall panels 14 a′, 14 b′ form the respective side walls 12 a, 12 b and the end walls 14 a, 14 b, respectively. As noted hereinabove, the end walls 14 a, 14 b and the side walls 12 a, 12 b can be defined as plurality of side walls 12 a, 12 b, 14 a, and 14 b. The blank B1 is also divided by two parallel longitudinal parallel fold lines 60, 62 perpendicular to transverse fold lines 54, 56, and 58, although longitudinal fold lines 60, 62 may be oriented at some angle relative to one another or relative to transverse fold lines 60, 62. The four bottom panels 16 a′, 16 b′, 16 c′, and 16 d′are formed from intersection of the longitudinal fold line 60 in combination with the three transverse parallel fold lines 54, 56, and 58. When the four bottom panels 16 a′, 16 b′, 16 c′, and 16 d′are in fully folded position, they define the bottom wall 16 of the container 10.

Each of the first slots 66 a, 66 b, and 66 c is cut into the first blank B1 between bottom panels 16 a′, 16 b, 16 c′, and 16 d′, respectively. Each of the first slots 66 a, 66 b, and 66 c is formed to facilitate the folding of the four bottom panels 16 a′, 16 b′, 16 c′, and 16 d′ in an overlapping relationship. Two spaced apart second slots 67 a, 67 b are formed on the side wall 12 a′ near the fold line 62 which are used to construct the bumper sticker panel 22 when the blank is fully constructed and will be discussed in greater detail hereinafter. Each of the end wall panels 14 a′, 14 b′ and the side wall 12 b′ includes a respective shoulder 20′ that is formed by the parallel fold lines 62 and 64. Each of the respective end wall panels 14 a′, 14 b′ includes three folding flaps 100 a, 100 b, 100 c and 100 d, 100 e, and 100 f. For example, the three folding flaps 100 a, 100 b, 100 c are foldably joined to one another and the other three folding flaps 100 d, 100 e, and 100 f are foldably joined to one another. The end wall panels 14 a′, 14 b′ are mirror image of one another when the blank is fully constructed. The folding flaps 100 a, 100 b, and 100 c are foldably connected to one another by two parallel rows of folding hinges 102. Similarly, the folding flaps 100 d, 100 e, and 100 f are foldably connected to one another by two parallel rows of folding hinges 102. The respective folding flaps of the end wall panels 14 a′, 14 b′ and the side wall 12 b′foldably extend from the lateral edges of respective end wall panels 14 a′, 14 b′ and the side wall 12 b′. In this example, there are three folding hinges 102 in each row. In addition, the side wall 12 b′ includes folding flaps 100 g, 100 h, and 100 i that are foldably connected to one another by two parallel rows of folding hinges 102. The end wall panel 14 b′ further includes a glue flap 72 which is used to be attached to the side wall panel 12 b′ when the blank B1 is fully constructed. The glue flap 72 foldably extends from the free edge of the end wall panel 14 b′. The side wall panel 12 a′ includes the bumper sticker panel 22′ defined by the fold line 62. The bumper sticker 22′ constructed from two panels 22 a′, 22 b′ that overlapped on one another along fold lines 104.

An extension strip 106 is defined by cutline 108 which is foldably extended from panel 22 a′. Two spaced apart tabs 110 a, 110 b are formed on the cutline 108 which is the boundary of the extension strip 106 and the panel 22 a′. The respective tabs 110 a, 110 b is inserted into corresponding second slots 67 a, 67 b when the two panels 22 a′, 22 b′ are in overlapping relationship with one another for constructing the bumper sticker 22. Four generally-shaped-miters 112 are cut on the panel 22 a′ and the extension strip 106, which in turn, form respective first ears 114 a, 114 b and respective second ears 116 a, 116 b. The combination of two panels 22 a′, 22 b′ including the respective ears 114 a, 114 b, 116 a, 116 b, when folded, form and lock-in the bumper sticker panel with the side wall panel 12 a′. It locks over the ears 114 a, 114 b, 116 a, 116 b and stabilizes the container opening. The extensions on the inside parts of the locking mechanism further hold the columns into place. When the two panels 22 a′, 22 b′ including the respective first and second ears 114 a, 114 b and 116 a, 116 b are firmly in the folded position, the container is configured so that the unfolding of the container 10 would not be readily easy. In the first step of folding sequences, blank B1 is folded so that the glue panel 72 is attached to the side wall panel 12 b′ as best shown in FIG. 5.

FIGS. 4 through 13 illustrate the folding sequences of the blank B1 for constructing shipping and display container 10 in accordance to the present invention. Although the manual set-up of the shipping and displaying container 10 is easily accomplished, however, an ordinary skilled in the art would appreciate that generally a folding machine may alternatively performs the forming operations. It should be noted that the proper size and configuration of these panels are important to construct into side and end panels that are brought into juxtaposition with one another to form the shipping and display container 10. In the first step of the folding sequences, end wall panel 14 b′ is folded onto the side wall panel 12 a′ along the fold line 58 and the side wall panel 12 b′ is folded onto the end wall panel 14 a′ along the fold line 54. Next, the glue flap 72 is glued to the longitudinal edge of the side wall panel 12 b′. After the first step of folding as described with respect to the FIGS. 4 and 5, the bottom panel 16 a and 16 c are brought into juxtaposition and the bottom panels 16 b, 16 d are glued to the bottom panel 16 a, 16 c. Alternatively, once the bottom panels 16 b, 16 d are also brought into juxtaposition, they can be enclosed the bottom wall 16 by glue tape. Next, folding the top portion of the container 10 by folding the panel 100 g onto the panel 100 h along the folding hinge 102 and continue folding over the panel 100 i toward inside of the container 10 and then press fit against inside of the side wall 12 b so that a top beam is formed as depicted in FIG. 8. Next, to form the first column, folding panel 100 a onto the panel 100 b along the folding hinge 102 and continue folding over the panel 100 c toward inside of the container 10 and then press fit against inside of the side wall 12 b so that the first column is formed as depicted in FIG. 9. The extension strip 106 further enhances the bumper sticker 22 to remain in locking position. Next, repeat to form the second column on the opposite side as just described as depicted in FIGS. 10-12. The beam across the top of the container is supported by left and right columns. Finally, the bumper sticker panel 22 is constructed by first folding the extension strip 106 along the cutline 108 over the panel 22 a′ and then folding panel 22 a′ onto the panel 22 b′ in an overlapping relationship and respective tabs 110 a, 110 b is inserted into corresponding second slots 67 a, 67 b when the two panels 22 a′, 22 b′ are in overlapping relationship with one another and the back of the bumper sticker panel 22 has reverse folds that lock it in position from three directions as the container is fully constructed.

In use, after products such as poultry or the like are disposed in the container, as an alternative generally for shipping purposes, the top plug panel 26 covers the opening 18. As best depicted in FIG. 1, the top plug panel 26 is secured by inserting the extension tab 34 underneath of the bumper sticker panel 22 and the respective detachable latch tab 46 a, 46 b are inserted into the respective handhold openings 24 a, 24 b such that the respective hinge tab 25 a, 25 b securely hold in place the respective ears 50 a, 50 b. To open the container 10, the pulling section 40 is snapped upwardly so that the top plug panel 26 is permanently detached from the container 10 along the cut lines 48 a and 48 b. Then the container 10 can be rotated 90 degrees to be placed in display position.

In sum, the shipping and display container comprises a plurality of respective side walls and respective end walls that are foldably joined to one another. One of the plurality of respective side walls includes two spaced apart second slots formed thereon. The bottom wall flaps are foldably joined to bottom edges of the plurality of respective side walls and end walls and folding inwardly therefrom into overlapping relationship with one another to form a bottom wall closure. A respective plurality of beams are foldably joined to the respective plurality of side walls and end walls and each of the plurality of beams is defined by a shoulder panel and three folding flaps foldably joined to one another to form one of the respective plurality of beams. a bumper sticker panel is defined by two panels and an extension strip foldably joined to one another in which the two panels are coextensively folding onto one another and the extension strip is outwardly extending from a free edge of one of the two panels. The bumper sticker panel includes two spaced apart tabs formed between a boundary of the extension strip and one of the two panels. Each of the spaced apart tabs is inserted into the corresponding second slots. The bumper sticker panel is foldably joined to upper edge of one of the plurality of side walls forming a partial top closure when the open-top container is in the shipping position and partially prevent products from falling out when the container is in the display position.

It should now be appreciated that the present invention provides a material-saving, quickly erected carton especially useful in retaining, transporting variety of products such as poultry or meat, by way of example. The shipping and display container 10 is designed with first, and second columns, a cross beam and a bumper sticker panels to securely hold the container in shipping as well as display position. As described above, the structure of the end panels, the side panels with the first and second columns, the cross beam and the bumper sticker panels enhance the rigidity, stackability, venting capability and manufacturing cost effectiveness of the shipping and displaying container. The blank used to form the shipping and display container has a symmetrical design, which reduces the erecting and closing labor. The lay flat design of the blank speeds the cutting and packaging process and facilitates easy shelving.

Numerous modifications and variations on the present invention are possible in light of the above teachings. It is, therefore, to be understood that within the scope of the accompanying claims, the invention may be practiced otherwise than as specifically described herein.

It should be understood that fold lines and score line as used herein may be used interchangeably so long as the function of the line is not destroyed.

While the invention has been described with reference to a preferred embodiment, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted without departing from the scope of the invention. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from its scope. Therefore, it is intended that the invention not be limited to the particular embodiment disclosed, but that the invention will include all embodiments falling within the scope of the appended claims. 

What is claimed is:
 1. A container for shipping and displaying products comprising: a plurality of respective side walls and respective end walls foldably joined to one another; bottom wall flaps foldably joined to bottom edges of the plurality of respective side walls and end walls and folding inwardly therefrom into overlapping relationship with one another to form a bottom wall closure; a respective plurality of beams foldably joined to the respective plurality of side walls and end walls wherein each of the plurality of beams being defined by a shoulder panel and a plurality of folding flaps foldably joined to one another; and a bumper sticker panel being defined by two panels and an extension strip foldably joined to one another wherein the two panels being coextensively folding onto one another and the extension strip being outwardly extending from a free edge of one of the two panels and wherein the bumper sticker panel foldably joined to upper edge of one of the plurality of side walls forming a partial top closure when the open-top container is in the shipping position and partially prevent products from falling out when the open-top container is in the displaying position.
 2. The container of claim 1 wherein the plurality of folding flaps includes three flaps coextensively folding onto one another to form one of the respective plurality of beams.
 3. The container of claim 1 wherein one of the plurality of respective side walls includes two spaced apart second slots formed thereon.
 4. The container of claim 1 wherein the bumper sticker panel includes two spaced apart tabs formed between a boundary of the extension strip and one of the two panels and wherein each of the spaced apart tabs are inserted into the corresponding second slots formed on one of the plurality of the side walls.
 5. The container of claim 1 further comprising a top plug panel used to enclose the container when the container is in the shipping position.
 6. A shipping and display container comprising: a plurality of respective side walls and respective end walls foldably joined to one another, one of the plurality of respective side walls includes two spaced apart second slots formed thereon; bottom wall flaps foldably joined to bottom edges of the plurality of respective side walls and end walls and folding inwardly therefrom into overlapping relationship with one another to form a bottom wall closure; a respective plurality of beams foldably joined to the respective plurality of side walls and end walls wherein each of the plurality of beams being defined by a shoulder panel and three folding flaps foldably joined to one another to form one of the respective plurality of beams; and a bumper sticker panel being defined by two panels and an extension strip foldably joined to one another wherein the two panels being coextensively folding onto one another and the extension strip being outwardly extending from a free edge of one of the two panels, the bumper sticker panel includes two spaced apart tabs formed between a boundary of the extension strip and one of the two panels and wherein each of the spaced apart tabs is inserted into the corresponding second slots and wherein the bumper sticker panel foldably is joined to upper edge of one of the plurality of side walls forming a partial top closure when the open-top container is in the shipping position and partially prevent products from falling out when the container is in the display position.
 7. A blank for making a shipping and display container comprising: two side wall panels and two end wall panels foldably joined together along adjacent side edges, one of the two end wall panels includes a glue panel adapted to form the side walls and the end walls in opposed relationship to one another in shipping and display container erected from the blank and one of the two side wall panels includes two spaced apart second slots formed thereon; a plurality of bottom wall flap panels foldably joined to bottom edges of the side wall and end wall panels, the bottom wall flap panels adapted to be folded inwardly to form a bottom wall closure; each of the two end wall panels and one of the two side wall panels includes a shoulder panel and three folding flaps foldably joined to one another to form one of respective plurality of beams; and the one of the side wall panels further includes a bumper sticker panel being defined by two panels and an extension strip foldably joined to one another wherein the two panels being coextensively folding onto one another and the extension strip being outwardly extending from a free edge of one of the two panels, the bumper sticker panel includes two spaced apart tabs formed between a boundary of the extension strip and one of the two panels and wherein each of the spaced apart tabs are inserted into the corresponding spaced apart second slots. 